Product Maintenance Information

Transcription

1 Product Maintenance Information Hercu-Link ir hain Hoist Models H3-075 and H3-100 Save These Instructions R Form MH56243 Edition 4 October Ingersoll-Rand

2 Only allow Ingersoll Rand trained technicians to perform maintenance on this product. For additional information contact Ingersoll Rand factory or nearest istributor. For additional supporting documentation refer to Table 1 Product Manuals on page 2. Manuals can be downloaded from The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased performance and increased maintenance and will invalidate all warranties. Original instructions are in English. Other languages are a translation of the original instructions. Refer all communications to the nearest Ingersoll Rand Office or istributor. Table 1: Product Manuals Publication Part/ocument Number Publication Part/ocument Number Product Safety Information Manual MH56295 Product Information Manual MH56402 Product Parts Manual MH56403 INSPETION Periodic Inspection ccording to SME 30.16, frequency of periodic inspection depends on the severity of usage: NORML HEVY SEVERE yearly semiannually quarterly- isassembly may be required for HEVY or SEVERE usage. Keep accumulative written records of periodic inspections to provide a basis for continuing evaluation. Inspect all the items in Frequent Inspection. lso inspect the following: 1. Fasteners. heck all rivets, split pins, capscrews and nuts. Replace if missing or tighten if loose. 2. ll omponents. Inspect for wear, damage, distortion, deformation and cleanliness. If external evidence indicates the need, disassemble. heck gears, shafts, bearings, sheaves, chain guides, springs and covers. Replace worn or damaged parts. lean, lubricate and reassemble. 3. Hooks. Inspect hooks carefully for cracks using magnetic particle or other suitable non-destructive method. Inspect hook retaining parts. Tighten, repair or replace if necessary. 4. Load hain Sheaves. heck for damage or excessive wear. Replace if necessary. Observe the action of load chain feeding through hoist. o not operate a hoist unless load chain feeds through hoist and hook block smoothly and without audible clicking or other evidence of binding or malfunctioning. 5. Motor. If performance is poor, disassemble motor and check for wear or damage to bearings and shafts. The parts should be cleaned, lubricated and reassembled. Replace worn or damaged parts. 6. rake. Raise a load equal to rated capacity of hoist 4 to 6 inches (100 to 150 mm) off floor and check ability of hoist to hold load without drift. If drift occurs, disassemble. Remove brake discs as described in the MINTENNE section. heck and clean brake parts each time hoist is disassembled. Replace brake friction discs if thickness is less than inch (1.83 mm), or if oil groove pattern is not clearly visible. 7. Supporting Structure. heck for distortion, wear and continued ability to support load. 8. TROLLEY (optional feature). heck that trolley wheels track beam properly and clearance between trolley wheel flanges and beam is correct. Refer to INSTLLTION section. heck that wheels and beam are not excessively worn. Inspect side plates for spreading due to bending. o not operate hoist until problems have been corrected. 9. Labels and Tags. heck for presence and legibility. Replace if necessary. 10. End nchors (Load hain). Ensure load chain end is securely attached. heck chain stopper is correctly installed on free end of load chain. 11. Load hain. Measure chain for stretching by measuring across five link sections all along chain, paying particular attention to most frequently reeved links. Refer to wg. MHP0041,. Gauge Length, on page 2. When any five-link section in working length reaches or exceeds discard length, listed in Table 3on page 2, replace entire chain. lways use genuine Ingersoll Rand replacement chain for regular and nickel-diffused load chains. When ordering load chain, specify which unit it will be used on. hain will then be cut and tagged with the right number of links. 12. hain ontainer (optional feature). heck for damage or excessive wear and that chain container is securely attached to hoist. Secure or replace if necessary. 13. Limit ssembly. heck limit arm moves freely. Table 2: Load hain Normal and iscard Length Hoist Model H3-025 H3-050 H3-075 H3-100 Load hain Length Inspection (wg. MHP0041) Records and Reports hain Size Normal Length iscard Length mm in. mm in. mm Gauge Length Inspection records, listing all points requiring periodic inspection should be maintained for all load bearing equipment. Written reports, based on severity of service, should be made on the condition of critical parts as a method of documenting periodic inspections. These reports should be dated, signed by person who performed inspection, and kept on file where they are readily available for review. Load hain Reports Records should be maintained documenting condition of load chain removed from service as part of a long-range load chain inspection program. ccurate records will establish a relationship between visual observations noted during frequent inspections and actual condition of load chain as determined by periodic inspection methods. 2 Form MH56243 Edition 4

3 INSPETION REPORT Model Number: Serial Number: Reason for Inspection: (heck pplicable ox) Ingersoll-Rand H3 ir Hoist 1. Scheduled Periodic Inspection Quarterly Semiannually Yearly 2. iscrepancy(s) noted during Frequent Inspection 3. iscrepancy(s) noted during maintenance 4. Other: ate: Inspected y: Operating Environment: Normal Normal Heavy Severe Refer to Product Maintenance Information Manual INSPETION section and to the appropriate National Standards and odes of practice for general inspection criteria. If in doubt about an existing condition, contact the nearest Ingersoll Rand distributor or factory for technical assistance. Fasteners Gears Shafts OMPONENT ONITION ORRETIVE TION Pass Fail Repair Replace earings --- Load earing Sheaves hain Guides Springs --- overs Hooks --- Top ottom NOTES ctual Hook Throat Width: inches / mm (Refer to Product Information Manual for min./max. acceptable widths.) Hook Twist --- Hook rack Test Method Used: ye Penetrant Magnetic Particle Other: ctual Hook Throat Width: inches / mm (Refer to Product Information Manual for min./max. acceptable widths.) Hook Twist --- Hook rack Test Method Used: ye Penetrant Magnetic Particle Other: Hook Latch --- rake (10% Load Test) --- rake (Visual Inspection) Tail Pin (End nchor) Load hain Supporting Structure Labels and Tags --- Other omponents (List in NOTES section) --- Working length(s) maximum wear: inches / mm (refer to Table 3, on page 2) Testing: Pass Fail NOTES 1. Operational (No Load) 2. Operational (10% Load) 3. Operational (Maximum Test Load*) * Refer to Load Test in MINTENNE section for testing information. This page may be photocopied and used by inspectors or maintenance personnel. Form MH56243 Edition 4 3

4 TROULESHOOTING This section provides basic troubleshooting information. etermination of specific causes to problems are best identified by thorough inspections performed by personnel instructed in safety, operation and maintenance of this equipment. The chart below provides a brief guide to common winch symptoms, probable causes and remedies. Symptom ause Remedy Hoist will not operate. No air supply to hoist, or too little FM or PSI. Valve or limit arm sticking. Emergency valve OFF. Pendant malfunction. Hoist is overloaded. Motor is damaged. Lubricator is low on oil. rake is not releasing ( OWN direction only). Valve or limit arm sticking. Load continues to move when ump valves not releasing. hoist is stopped. UP direction. Pendant lever sticking. Load continues to move when hoist is stopped. OWN direction. Valve or limit arm sticking. ump valves not releasing. rake is slipping. Hoist is overloaded. Pendant lever sticking. Main air valve travel is restricted. Hoist will not lift rated capacity. rake is not releasing. Hook can be lowered but not raised. Hook can be raised but not lowered. Load chain jumps on sheave or is making a snapping sound. Trolley (optional feature) Trolley will not stop or trolley wheels slip. ir-powered trolley does not operate. Hoist is overloaded. No air supply to hoist or too little FM or PSI. Exhaust is restricted. Motor is damaged. Motor or gearbox is out of oil. Hoist is overloaded. No air supply to hoist or too little FM or PSI. Pendant malfunction. rake is not releasing. rake piston seals leaking. Low air pressure. Pendant malfunction. Worn or rusted chain. Incorrect chain. Worn sheave or chain guide. heck PSI (bar) at hoist inlet. Refer to SPEIFITIONS section in Product Information Manual for correct FM (cu.m/min) and PSI (bar). heck limit arm for free movement. Reset Emergency valve and push ON button. heck PSI (bar) at pendant. Minimum operating pressure in pendant line is 55 PSI (380 kpa/3.8 bar). Reduce load to within rated capacity. Repair or replace. Refer to MINTENNE section on page 5. heck oil level in motor and gearbox. Fill lubricator. heck brake release circuit and PSI (bar) at brake inlet (55 PSI (380 kpa/3.8 bar) minimum). heck limit arm for free movement. heck pendant hose dump valves. heck lever and restore free movement. heck limit arm for free movement. heck pendant hose dump valves (old style pendants). heck brake springs and brake disc linings for wear. Refer to MINTENNE section. Reduce load to within rated capacity. heck lever and restore free movement. Reduce load to within rated capacity. heck PSI (bar) at hoist inlet. Refer to SPEIFITIONS section in Product Information Manual for correct FM (cu.m/min) and PSI (bar). heck limit arm and linkage for free movement. heck brake release circuit and PSI (bar) at brake inlet (55 PSI (3.8 bar) minimum). Inspect vents and replace muffler. heck for worn motor bearings. heck oil levels in motor and gearbox. Fill to recommended level. Reduce load to within rated capacity. heck at hoist power supply connection with hoist under load. Raise pressure to rated capacity. heck PSI (bar) at air inlet connection (green fitting) on pendant. No breather in gearbox. Remove solid square head plug in outboard end of gearbox only and install vented (breather) plug. heck PSI (bar) at brake inlet. (55 PSI (380 kpa/ 3.8 bar) minimum.) heck brake and pendant dump valves, if used (old style pendants). Install repair kit. Refer to Parts section. heck PSI (bar) at valve inlet. Raise pressure to rated capacity. heck PSI (bar) at yellow fitting connection on pendant. Refer to INSPETION section in Product Information Manual to determine wear limit. Replace if necessary. Replace with correct chain. Replace worn parts. apsized hook. orrect as described in MINTENNE section on page 5. Hoist not in line with load. Incorrectly reeved load chain. No oil on load chain. amaged beam. Excessive oil, grease or paint on track of beam. Trolley not spaced for beam clearance. Pendant lever sticking. Emergency valve in OFF position. No air supply to trolley or too little FM (cu. m/min.) or PSI (kpa/bar). lign hoist with load. o not yard or side pull. heck load chain is correctly reeved. Lubricate load chain. Repair or replace beam. lean off oil, grease or paint. heck trolley spacing. Refer to INSTLLTION section in Product Information Manual. heck lever and restore free movement. Reset Emergency valve and push ON button. heck PSI (bar) at trolley inlet. Refer to manufacturer s specifications. ontrol valve is sticking. Refer to MINTENNE section on page 5. No oil in trolley motor or gearbox. Wheels are obstructed. heck oil levels in trolley motor and gearbox and fill to required level. Remove obstruction. Motor is damaged. Repair or replace. Refer to MINTENNE section on page 5. 4 Form MH56243 Edition 4

5 MINTENNE WRNING Never perform maintenance on hoist while it is supporting a load. efore performing maintenance, tag controls: Only allow personnel trained in operation and service of this hoist to perform maintenance. fter performing any maintenance on hoist dynamically test hoist to 100% of its rated capacity, in accordance with SME standards, before returning hoist to service. Testing to more than 100% of rated capacity may be required to comply with standards and regulations set forth in areas outside the US. Shut off air system and depressurize air lines before performing any maintenance. Proper use, inspections and maintenance increase the life and usefulness of your Ingersoll Rand equipment. uring assembly, lubricate gears, nuts, capscrews and all machined threads with applicable lubricants. Use of antiseize compound and/or thread lubricant on capscrew and nut threaded areas prevents corrosion and allows for easy disassembly of components. Maintenance Intervals The Maintenance Interval hart below is based on intermittent operation of equipment for eight hours each day, five days per week. If equipment is in operation for more than eight hours a day or is operated in severe applications or environments, more frequent maintenance should be performed Ton Hoists hain Link (view facing Motor) E First Link hain Weld End Link F 75 Ton Hoist Only G hain Weld located on back side Interval Start of each shift Semiannually Yearly Maintenance heck Make a thorough visual inspection of hoist for damage. o not operate hoist if damage is found. Operate in both directions. Hoist must operate smoothly without sticking, binding or abnormal noises. heck operation of pendant control and brake. Inspect disc brake friction linings and sprag clutch assembly. lean or replace parts as required. Inspect hoist gearing, shafts and bearings for damage or wear. Repair or replace as necessary. heck all of supporting members, including trolley if used. Repair or replace as required. (wg. MHP2336) Load hain Link Load chain replacement for all hoist models can be accomplished efficiently and easily by using existing load chain to install new load chain. 1. Using an abrasive wheel, cut a section from end link of existing chain to form a link. Refer to wg. MHP2337 on page 5,. Link. 2. onnect new chain to old chain by inserting end of new chain into link. Make certain welds and links on new chain match positioning of welds and links on chain being replaced. For model-specific information, refer to the appropriate hoist model diagram in. (35 mm) isc rake djustment No disc brake adjustment is required. If brake fails to hold load, brake must be disassembled, inspected, repaired and tested prior to placing hoist in service. When any part of friction disc thickness measures in. (1.83 mm) or less, or if oil groove pattern is not clearly visible, friction discs must be replaced. Load hain Replacement Load hain Weld Placement It is suggested that a short length of 32 mm load chain be available when replacing hoist load chain. Feeding a short length of load chain through bottom block assembly or power head assembly prior to installing new load chain may simplify installation. Weld on perpendicular load chain must always face away from sheaves. Refer to wg. MHP0042 on page 5,. Load hain;. Standing Link;. Load Sheave;. hain Weld. Load hain Standing Link Load Sheave hain Weld (wg. MHP2337) Link UTION o not distort link in any manner. The link must be able to pass over chain sheaves without binding. etermining Twisted, Kinked or apsized Load hain Ensure chain is not twisted, kinked or capsized during installation. Refer to wg. MHP0020 on page 5,. ppearance of hain Not Twisted;. ppearance of hain Twisted; and wg. MHP0043 on page 6,. Make certain the bottom block has NOT been flipped through the chain falls. Twisted hain (wg. MHP0042) Replacement Load hain Link rrangement orrect load chain installation requires that load chain have either an even or odd number of total chain links. Refer to wg. MHP2336 on page 5 for illustration of how to determine chain arrangement;. hain Link (View From Motor); Ton Hoist;. First Link;. hain Weld; E. End Link; F. 75 Ton Hoist Only; G. hain Weld Located on ack Side. (wg. MHP0020) apsized hain ppearance of hain Not Twisted ppearance of hain Twisted Form MH56243 Edition 4 5

6 (wg. MHP0043) H3-025 Hoist Make certain bottom block has NOT been flipped through the chain falls Refer to wg. MHP2338 on page 6,. Weld;. Feed first link perpendicular to load sheave;. Power Head Load Sheave;. Hoist Motor Side; E. hain Stopper; F. Weld on perpendicular chain link must face away from top sheave. Weld on flat chain link must face away from hoist motor side; G. ottom lock. 1. The hoist should be installed and connected to air supply. Reduce hoist air pressure to 60 psi (4 bar/414 kpa). 2. Remove chain bucket, if used. 3. Remove load chain stopper. 4. Remove bottom block assembly. 5. ut new load chain to length. Load chain must have an even number of links (first and last links must be at 90 to each other). Refer to wg. MHP2336on page Run hoist slowly in lifting direction until load chain free end is approximately 2 ft. (0.6 m) from hoist. 7. Using a link which is the same size as load chain join new load chain to old taking care that weld on perpendicular links on new load chain are facing away from hoist load sheave. 8. Run hoist slowly until new load chain has passed 2 to 3 feet (0.6 to 1 m) through hoist. Remove link and old chain. 9. Install chain stopper in last link of load chain free end. 10. Install bottom block assembly. 11. Lubricate entire length of load chain before operating hoist. Refer to LURITION section in Product Information Manual. H3-025 hain Reeving Weld Feed first link perpendicular to load sheave Power Head Load Sheave Hoist Motor Side 4. Run hoist slowly in lifting direction until bottom block assembly is approximately 3 ft. (1 m) from hoist power head. Firmly support and secure bottom block assembly in this position. WRNING o not begin chain replacement until bottom block assembly is fully secured and supported. If bottom block assembly or chain are dropped, they could cause injury or damage property. 5. ut new load chain to length. Load chain must have an even number of links (first and last links must be at 90 to each other). Refer to wg. MHP2336 on page Remove pins that anchor load chain to power head assembly. 7. Using a link which is the same size as load chain join new load chain to free end on old chain taking care that weld on perpendicular standing links on new chain are facing away from hoist load sheave. 8. Run hoist slowly until new load chain has passed through hoist. ontinue running hoist and pull chain by hand through bottom block assembly. egin feeding chain at position and work alphabetically. Remove link and old chain. 9. nchor end of load chain to power head assembly. Install chain stopper in last link of load chain free end. 10. Lubricate entire length of load chain before operating hoist. Refer to LURITION section in Product Information Manual. H3-050 hain Reeving Feed first link perpendicular to load sheave E hain Stopper Weld Power Head Load Sheave F Hoist Motor Side H nchor hain at this point Weld on perpendicular chain links must face away from sheaves Weld on flat chain links must face away from hoist motor side G ottom lock hain Stopper F E Weld on perpendicular chain link must face away from top sheave Weld on flat chain link must face away from hoist motor side (wg. MHP2338) H3-050 Hoist G ottom lock Refer to wg. MHP2339 on page 6,. Weld;. Feed first link perpendicular to load sheave;. Power Head Load Sheave;. Hoist Motor Side; E. hain Stopper; F. Weld on perpendicular chain links must face away from sheaves. Weld on flat chain links must face away from hoist motor side; G. ottom lock; H. nchor hain at this point. 1. The hoist should be installed and connected to air supply. Reduce hoist air pressure to 60 psi (4 bar/414 kpa). 2. Remove chain bucket, if used. 3. Remove load chain stopper. (wg. MHP2339) H3-075 Hoist Refer to wg. MHP2340 on page 7,. Feed first link flat to load sheave;. Weld on perpendicular chain links must face away from sheaves;. hain Stopper;. nchor chain at this point; E. Weld on flat chain links must face away from hoist motor side; F. Power Head Load Sheave; G. Power Head Idle Sheave; H. Hoist Motor Side; J. ottom lock; K. 75 Ton Hoist Only; L. hain Weld; M. hain Weld located on back side. 1. The hoist must be installed and connected to air supply. Reduce hoist air pressure to 60 psi (4 bar/414 kpa). 2. Remove chain bucket, if used. 3. Remove chain stopper. 4. Run hoist slowly in lifting direction until bottom block assembly is approximately 3 ft. (1 m) from hoist power head. Firmly support and secure bottom block assembly in this position. WRNING o not begin chain replacement until bottom block assembly is fully secured and supported. If bottom block assembly or chain are dropped, they could cause injury or damage property. 6 Form MH56243 Edition 4

7 5. ut new load chain to length. Load chain must have an odd number of links (first and last links must be in same plane/parallel to each other). Refer to wg. MHP2336 on page Remove capscrew and cotter pin that anchor load chain to bottom block assembly. 7. Using a link which is same size as load chain, join new load chain to free end on old chain taking care that weld on perpendicular standing links on new chain are facing away from hoist load sheave. 8. Run hoist slowly until new load chain has passed through hoist. ontinue running hoist and pull chain by hand through bottom block assembly. egin feeding chain at position and work alphabetically. Remove link and old chain. 9. ttach end of load chain to bottom block assembly. Install chain stopper in last link of load chain free end. 10. Lubricate entire length of load chain before operating hoist. Refer to LURITION section in Product Information Manual. H3-075 hain Reeving Feed first link flat to load sheave Weld on perpendicular chain links must face away from sheaves hain Stopper nchor chain at this point F Power Head Load Sheave G Power Head Idle Sheave Hoist Motor Side H J ottom lock 7. Using a link which is the same size as load chain join new load chain to free end on old load chain taking care that weld on perpendicular standing links on new load chain are facing away from hoist load sheave. 8. Run hoist slowly until the new load chain has passed through hoist. ontinue running hoist and pull chain through bottom block assembly. egin feeding chain at position and work alphabetically. Remove link and old chain. 9. nchor end of load chain to power head assembly. Install chain stopper in last link of load chain free end. 10. Lubricate entire length of load chain before operating hoist. Refer to LURITION section. H3-100 hain Reeving Feed first link perpendicular to load sheave nchor chain at this point hain Stopper E Weld Power Head Load Sheave Idle Sheave Hoist Motor Side E F G E Weld on flat chain links must face away from hoist motor side M K L 75 Ton Hoist Only hain Weld hain Weld located on back side J H ottom lock Weld on perpendicular chain links must face away from sheaves Weld on flat chain links must face away from hoist motor side (wg. MHP2340) H3-100 Hoist Refer to wg. MHP2341 on page 7,. Feed first link perpendicular;. nchor chain at this point;. hain Stopper;. Weld; E. Power Head Load Sheave; F. Idle Sheave; G. Hoist Motor Side; H. ottom lock; J. Weld on perpendicular chain links must face away from sheaves. Weld on flat chain links must face away from hoist motor side. 1. The hoist must be installed and connected to air supply. Reduce hoist air pressure to 60 psi (4 bar/414 kpa). 2. Remove chain bucket, if used. 3. Remove chain stopper. 4. Run hoist slowly in lifting direction until bottom block assembly is approximately 3 ft. (1 m) from hoist power head. Firmly support and secure bottom block assembly in this position. WRNING o not begin chain replacement until bottom block assembly is fully secured and supported. If bottom block assembly or chain are dropped, they could cause injury or damage property. 5. ut new load chain to length. Load chain must have an even number of links (first and last links must be at 90 to each other). Refer to wg. MHP2336 on page Remove pins that anchor load chain to power head assembly. (wg. MHP2341) General isassembly The following instructions provide the necessary information to disassemble, inspect, repair, and assemble the hoist. omplete assembly drawings of the hoist components are provided in Product Parts Information Manual. If hoist is being completely disassembled for any reason, follow the order of the topics as they are presented. It is recommended that all maintenance work on hoist be performed on a bench in a clean dust-free work area. In the process of disassembling hoist, observe the following: 1. Turn off air system and depressurize air lines before performing any maintenance. isconnect hoses from hoist and trolley. Plug or cap openings to keep out dirt and contaminants. 2. Never disassemble hoist any further than is necessary to accomplish the needed repair. good part can be damaged during the course of disassembly. 3. Never use excessive force when removing parts. Tapping gently around the perimeter of a cover or housing with a soft hammer, for example, is sufficient to break the seal. 4. o not heat a part with a flame to free it for removal, unless the part being heated is already worn or damaged beyond repair and no additional damage will occur to other parts. 5. In general, hoist is designed to permit easy disassembly and assembly. The use of heat or excessive force should not be required. Form MH56243 Edition 4 7

8 6. Keep the work area clean to prevent dirt and other foreign matter from getting into bearings and other moving parts. 7. ll seals and O rings should be discarded once they have been removed. New seals and O rings should be used when assembling the hoist. 8. When grasping a part in a vise, always use leather or copper covered vise jaws to protect the surface of part and help prevent distortion. This is particularly true of machined surfaces, threaded members and housings. 9. o not remove any part which is press fit in or on a subassembly unless the removal of that part is necessary for repairs or replacement. 10. To avoid damaging bearings during hoist assembly or disassembly always tap or press on bearing inner race for shaft fit bearings or outer race for bore fit bearings. UTION Use extreme care when performing any maintenance on hoist. Hoist weight may exceed 7,400 lbs (3357 kg) use appropriately rated equipment for moving. Powerhead isassembly Refer to wg. MHP Remove chain from hoist, by removing retainer ring (171) and chain anchor pin (170) from lead stripper (159). 2. isconnect all hoses from hoist motor. rain oil from reducer, brake and motor assemblies. 3. Place powerhead assembly in horizontal position and support on blocks. 4. Remove capscrews (703) and lockwashers (702) from motor assembly. 5. Remove motor assembly using the proper equipment necessary to support weight of the component. 6. If motor repair or general maintenance is required refer to Motor isassembly section on page Remove limit arm (301) as an assembly by removing capscrew (303) that secures it to motor end frame (152). It is not necessary to remove valves (312) or spacers (304) unless damaged. 8. Using side holes in frames (154) and (153), rotate powerhead assembly vertically with motor end frame (152) down. Place blocks along either side of motor end frame (152) to protect brake shaft (102) from damage. 9. Remove capscrews (202) and lockwashers (702) that secure reduction gear assembly (200). 10. Using the proper equipment necessary to support weight of component, remove reduction gear assembly from reduction gear frame end (154) taking care not to damage or distort the drive shaft (151). 11. It is not recommended to disassemble reduction gear. 12. Remove drive shaft (151) taking care not to damage teeth or distort shape. 13. It is not recommended to remove bushing (169) from drive shaft (151). 14. Remove capscrews (161) and (162) from reduction gear end frame (154) and pry from center frame (153). 15. Remove capscrews (166) and wear pads (158) from reduction gear end frame (154) and center frame (153). heck wear pads (158) for damage or wear. Refer to INSPETION in Product Maintenance Information Manual. 16. Remove drive sheave (155) and lead stripper (159) at the same time. arefully pry from center frame (153) both drive sheave and lead stripper. It may be necessary to use a rubber mallet to loosen lead stripper from dowel pins (168). owel pins (168) do not need to be removed. 17. Remove O rings (163) and (164) and bearings (157) from drive sheave (155). iscard O rings. 18. Using side holes on frames (152) and (153), rotate motor end frame (152) so that motor end frame side is up, this will make disassembly of brake easier. NOTIE rake assembly is spring loaded, use care when removing motor adapter (53). 19. Remove capscrews (109) from brake housing (110), and carefully remove motor adapter (53), springs are located between reaction ring (101) and piston (104). 20. Remove reaction ring (101) and piston (104). 21. Remove O ring (116) and discard. 22. Remove from piston (104), seals (113) and (114), check for damage or wear. 23. Remove brake shaft (102) as an assembly, then remove drive discs (111) and friction discs (112), check for wear. 24. Remove retainer ring (108) and thrust washer (107) from brake shaft assembly. 25. It is not recommended to remove from brake shaft (102) the hub (103), sprag clutch (105) or bushings (106), unless damage or wear is visible. 26. Remove brake housing (110) and O ring (123) from motor end frame (152). iscard O ring. 27. Remove capscrews (161) from motor end frame (152) and pry center frame (153) from motor end frame. It is not necessary to remove dowel pins (165). 28. Remove idler sheave assembly (156) from motor end frame (152). 29. Remove O rings (163) and (164) and bearings (157) from idler sheave (156). iscard O rings. Top Hook isassembly Refer to wg. MHP Remove hoist from mounting structure. 2. To remove hook and plate assembly (hook cannot be removed before hook plate) remove capscrews (403) and separate hook plate assembly from power head. 3. To remove hook (352) from hook plate (400) drive out roll pins (355) and remove nut (353) from threaded hook end. 4. Remove hook (352) and bearing (354) from hook plate (400). UTION o not use swivel ring hook (401) for lifting load, use for installation only. ottom lock isassembly H3-100 Hoist Refer to wg. MHP lways make sure load chain is removed before disassembly. 2. Remove capscrews (356) securing hook blocks (351) to hook center block (350) and pry hook blocks (351) from both sides of hook center block (350). (Engagement of dowel pins (165) may make removal difficult). 3. rive out pins (355) from nut (353) in threaded hook section. Pull hook (352) from hook center block (350) and remove bearing (354) and nut (353). 4. Remove bearings (157), sheaves (156) and O Rings (163) and (164) from hook blocks (351) and hook center block (350). iscard O Rings (163) and (164). Hoist Motor isassembly Refer to wg. MHP Remove five capscrews (109) from exhaust flange (744). o not remove the two capscrews (747) from throttle valve assembly (260). 2. Remove pilot control valve housing (621) by pulling it out of motor housing (720) as an assembly with exhaust flange (744). UTION o not remove the exhaust flange (744) until rotary valve (740) has been removed from rotary valve housing (739). 3. Remove rotary valve (740) by pulling it out from assembly through the motor housing end of rotary valve housing (739). 4. Remove exhaust flange (744) and control valve assembly (621) by removing capscrews (747) and (749), respectively. 5. Remove each cylinder head (705) by removing four capscrews (704). Remove head gasket (713). 6. Pull cylinder liner (701) straight out. 7. Position piston (708) at top of its stroke. In this position, with cylinder liner pulled out in step 6, wrist pin (707) can be removed. Remove one retainer ring (709) from either side of piston (708). Push wrist pin (707) out by hand from one side. If wrist pin is too tight it is acceptable to carefully heat piston to 200 F (93 ) or less and then push wrist pin out. NOTIE If piston, wrist pin, connecting rod or cylinder liner are to be re-assembled, number each set. lso add radial alignment marks for each piston and cylinder liner to motor housing. 8. Remove remaining cylinder liners and pistons as described in steps 6 and 7. To remove crank assembly, all pistons and cylinder liners must be removed. 9. rank assembly (727) can now be removed with oil slinger (726) by pulling straight out from motor housing (720). Use care while guiding connecting rods (710) through inside of motor housing. 2 Lever Pendant isassembly Refer to wg. MHP Remove fittings (265) and lifting eye (250). 2. Unscrew plugs (254). Remove springs (255) and balls (256). 3. Tap out pin (257) and remove levers (263). 4. Remove setscrews (260) from pendant handle (264). 5. Remove valve assemblies (262). Remove O rings (253) and (259) and protector (261) from valve assemblies. iscard O rings. 6. Remove plug (270) from pendant handle (264). 7. Remove retainer ring (268) and exhaust washer (267). 4 Lever Pendant isassembly Refer to wg. MHP Remove fittings (265) and lifting eye (250). 2. Unscrew plugs (254). Remove springs (255) and balls (256). 3. Remove capscrews (280) and (283) and washers (281) from attachment (left) (286). Remove attachment (left) taking care not to damage pin (284). Separate pin (284), lever (257) and O rings (282) from attachment (left). iscard O rings. 4. Repeat step 3 for attachment (right) (287). 5. Tap out pin (257) and remove levers (263). 6. Remove valve assemblies (262). Remove O rings (253) and (259) and protector (261) from valve assemblies. iscard O rings. 7. Remove plug (270) from pendant handle (264). 8. Remove retainer ring (268) and exhaust washer (267). leaning, Inspection and Repair Use the following procedures to clean, inspect, and repair the components of the hoist. leaning lean all hoist component parts in solvent (except for the friction discs). The use of a stiff bristle brush will facilitate the removal of accumulated dirt and sediments on the gears and frames. If bushings have been removed it may be necessary to carefully scrape old Loctite from the bearing bores. ry each part using low pressure, filtered compressed air. 8 Form MH56243 Edition 4

9 UTION earings that are loose, worn or rotate in the housing must be replaced. Failure to observe this precaution will result in additional component damage. o not use trichloroethylene to clean parts. If trolley suspension yoke bushings are loose or worn they must be replaced. Failure to observe this precaution will result in additional component damage. Inspection ll disassembled parts should be inspected to determine their fitness for continued use. Pay particular attention to the following: 1. Inspect all gears for worn, cracked, or broken teeth. 2. Inspect all bushings for wear, scoring, or galling. 3. Inspect shafts for ridges caused by wear. If ridges caused by wear are apparent on shafts, replace the shaft. 4. Inspect all threaded items and replace those having damaged threads. 5. Measure the thickness of the friction discs (112). If the friction discs are less than in. (1.83 mm) or if oil groove pattern is not clearly visible replace the friction discs (112). 6. heck mufflers (173) and (176) for damage or excessive dirt. 7. Inspect trolley yoke bushings for wear, scoring, or galling. If wear exceeds discard dimensions in Table 9 replace bushings. 8. heck bearings for ease of rotation and wear. Replace bearings if rotation is rough or bearings are excessively worn. 9. heck the sprag clutch assembly for wear, flat spots on the sprags or damage. If any of these conditions exist, replace parts. 10. Inspect sprag clutch wear area on brake hub (103) and on brake shaft (102) for ridges or galling. If either condition exists replace parts. NOTIE 9. Lubricate and install O rings (163), (164) and bearings (157) on both sides of drive sheave (155). 10. Install dowel pins (165) and (168) if removed during disassembly. 11. Install drive sheave assembly (155) and lead stripper (159) together. lign dowel pins (168) in lead stripper with holes in center frame (153). 12. Install a short length of chain around drive sheave (155) and lead stripper (159). Refer to Load hain Weld Placement and wg. MHP0042 in MINTENNE section on page Install reduction gear end frame (154) onto center frame (153) being careful to align dowel pins (165) and (168). 14. Install capscrews (161) and (152) in reduction gear frame and torque to approximately 909 to 1030 ft lbs (1299 to 1471 Nm). 15. Using holes on both sides frames, rotate powerhead assembly so reduction gear frame (154) side is down for easier installation of brake. 16. Lubricate and install O ring (123). lign capscrew holes and position brake housing (110) on motor end frame (152). NOTIE If hub (103) and sprag clutch (105) were removed from brake shaft (102) be sure to install this assembly so teeth of hub (103) are pointing toward motor end frame (152). 17. lean brake shaft assembly and inspect parts for wear before assembling brake. 18. Install on brake shaft (102), hub assembly (103) and thrust washer (107) secure with retainer ring (108). 19. Inspect and install drive discs (111) and friction discs (112) on hub (103). lternate discs, starting with friction disc (112) followed by a drive disc (111). 20. Lubricate and install seals (113) and (114) in brake piston (104) grooves so seal lips face each other. o not overstretch seals during this procedure. Refer to wg. MHP0139 on page Install brake shaft assembly (102) and piston assembly (104) in brake housing (110). 22. Install brake piston assembly in brake housing so stepped side enters first. Gently tap into position using a soft mallet until seated. Refer to wg. MHP0139,. Seal Lip;. Seal;. rake Piston. If brake hub (103), sprag clutch (105) or brake shaft (102) require replacement, it is recommended that all three parts be replaced at the same time. Seal Lip Table 3: ushing Inspection Specifications Hoist Model H3-025 Item No. ushing Part No. Original ore Size iscard ore Size in. mm in. mm H ontact Factory H H3-100 Seal rake Piston Repair ctual repairs are limited to the removal of small burrs and other minor surface imperfections from gears and shafts. Use a fine stone or emery cloth for this work. 1. Worn or damaged parts must be replaced. Refer to the applicable parts listing for specific replacement parts information. 2. Inspect all remaining parts for evidence of damage. Replace or repair any part which is in questionable condition. The cost of the part is often minor in comparison with the cost of redoing the job. 3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings. 4. Examine all gear teeth carefully, and remove nicks or burrs. 5. Polish the edges of all shaft shoulders to remove small nicks which may have been caused during handling. 6. Remove all nicks and burrs caused by lockwashers. 7. Replace all seals, 'O' rings and gaskets. ssembly Instructions UTION Use extreme care when performing any maintenance on hoist. Hoist weight may exceed 7,400 lbs (3357 kg) use appropriately rated equipment for moving. Refer to Product Parts Information Manual for assembly drawings and parts lists. Powerhead ssembly Refer to wg. MHP Place motor end frame in a vertical position with motor side down, for procedures 2 through Lubricate and install O rings (163) and (164) and bearings (157) to idler sheave (156). 3. Install idler sheave assembly (156) in motor end frame (152) and install a short length of chain. Refer to Load hain Weld Placement and wg. MHP0042 in MINTENNE section on page If vertical stripper (160) was removed during disassembly, install and secure using capscrews (167) to center frame (153). 5. Install pins (165) if removed during disassembly. 6. lign pins (165) in motor end frame (152) with center frame (153) and carefully lower center frame onto motor end frame using appropriately rated equipment. 7. Install capscrews (161) and torque to approximately 909 to 1030 ft lbs (1299 to 1471 Nm). 8. Install wear pads (158) with capscrews (166) in reduction gear end frame (154) and center frame (153). pply a small amount of Loctite 242 to threads. (wg. MHP0139) 23. Install springs (117), O ring (116) and reaction ring (101) on brake shaft (102). 24. Install motor adapter (53) to brake housing (110) and secure with capscrews (109). Torque to approximately 106 to 121 ft lbs (151 to 173 Nm). 25. Using side holes in frames of hoist rotate hoist assembly vertically so motor end frame (152) is down. Place blocks along either side of motor end frame (152) to protect brake shaft (102) from damage. 26. Install drive shaft (151) and bushing (169) through reduction gear end frame side so it engages with brake shaft. Use care when installing so no damage will occur to either shaft. 27. Rotate drive shaft (151) clockwise and check for brake shaft (102) to rotate. If brake shaft does not move, gently rotate drive shaft (151) until teeth engage brake shaft. ontinue this step until brake shaft (102) rotates with drive shaft. NOTIE Use care when installing reduction gear assembly (200) to powerhead assembly. amage or distortion to drive shaft (151) may occur if not properly supported while installing reduction gear assembly. 28. Install reduction gear assembly (200) to reduction gear end frame (154) and secure with capscrews (202) and lockwashers (702), apply a small amount of Loctite 242 to threads of capscrews. Torque to 80 to 90 ft lbs (114 to 129 Nm). 29. Using holes on both sides of frames, rotate powerhead assembly horizontally, providing blocks on either side for support. 30. Install motor assembly (700) to motor end frame (152) and secure with capscrews (703) and lockwashers (702), apply a small amount of Loctite 242 to threads of capscrews. Torque to 80 to 90 ft lbs (114 to 129 Nm). 31. fter chain has been reeved, install cotter pin (170) in lead stripper (159) and secure with retainer ring (171). Refer to wg. MHP2341 on page 27. Hoist Motor ssembly Refer to wg. MHP ssemble pilot control valve assembly (621) and manifold (750) to rotary valve housing (739) using four capscrews (747) and lockwashers (749). Install two capscrews (747) and lockwashers (749) that attach exhaust flange (744) to throttle valve housing. Form MH56243 Edition 4 9

10 2. Tighten capscrews (747) and (749) to 25 ft lbs (34 Nm). Throttle handle should move fully left and right without sticking or binding, and should center (by spring force) automatically when released. 3. Install two seal rings (741) on each end of rotary valve (740). Place bearing (742) onto the rear of rotary valve (740) and press into position. Press only on bearing inner race. With rotary valve housing (739) exhaust flange down, install rotary valve into housing. 4. Install O ring (737) into motor housing (720). 5. Install rotary valve housing gasket (812) onto rotary valve housing. With exhaust flange down on bench, install motor housing (720) onto rotary valve housing. heck for any evidence of damage to O ring when rotary valve housing is fully engaged. Install and tighten capscrews (109) to 50 ft lbs (68 Nm). 6. If removed, press crank bearing (724) on crank assembly (727). pply pressure only on inner race of bearing. 7. Place crank assembly on a work bench with oil slinger (726) down and slide the sleeve (728) (with tang up) on crankpin. 8. Slide connecting rod bushing (729) over sleeve (728) and first connecting rod ring (730) with chamfer up. 9. Install connecting rods (710) in same order as removed, with all feet pointing in same direction, using first connecting rod ring (730) to hold one side of connecting rod feet. 10. Slide second connecting rod ring over other side of connecting rod feet with chamfer on ring facing down (toward stem of connecting rod). 11. Slide crank shaft valve end over crank pin while simultaneously aligning tang on sleeve (728) with slot in crank shaft. 12. Rotate and position crank shaft valve end relative to crank pin to allow installation of lock pin (731). 13. Tap lock pin (731) in place and install pin nut (733). Torque nut to 60 ft lbs (81 Nm). 14. Install cotter pin (732) and bend ends over. 15. Install roll pin (734) and bearing (742) into valve end of crank shaft. 16. heck that all connecting rods move freely around crank. Position crank assembly into motor housing (720). Ensure bearing (724) is seated and connecting rods (710) are centered in cylinder holes. NOTIE Make certain roll pin (734) and three lugs on rotary valve (740) line up with corresponding hole and lugs on crank shaft. o not allow rotary valve to slide back in rotary valve housing (739). If rotary valve slides in too far, seal ring (741) will lock-up in internal grooves of rotary valve housing (739) and restrict further assembly. 17. Rotate crank assembly until one connecting rod (710) is at the top of its stroke. Install a piston (708) with its rings (706) and (711) to connecting rod with wrist pin (707) and retaining rings (709). 18. Install a new cylinder head gasket (713) before installing cylinder liner (701). 19. Install cylinder liner over the piston by compressing both piston rings and with a single band ring compressor. 20. Install cylinder head (705) over cylinder and secure cylinder head to motor housing with four capscrews (704). Torque capscrews to 60 ft lbs (81 Nm). 21. Repeat Steps 17 through 20 with remaining cylinders. 22. Rotate motor by hand. Motor should rotate without binding. 23. Install mounting flange (52) and gasket (722) on front of motor housing. Make sure notches on both parts are aligned. 24. Lightly lubricate O ring (737) and install in groove on motor adapter. 25. Temporarily install capscrews and nuts finger tight to retain motor adapter. 26. Install eye bolts and vent cap assembly (715) in motor housing. 27. Ensure oil drain and level plugs (712) are installed. Top Hook ssembly Refer to wg. MHP Install hook (352) and bearing (354) in hook plate (400). 2. Install nut (353) on threaded hook end until snug. ack nut (353) off until first dowel pin hole is lined up. Install pins (355). o not attempt to drive pins (355) into nut until holes are aligned or threads on hook (352) will be damaged. 3. Install hook plate assembly on power head with capscrews (403). Torque to approximately 1288 ft lbs (1840 Nm). 4. Install hoist on mounting structure. UTION o not use swivel ring hook (401) for lifting load, use for installation only. ottom lock ssembly H3-100 Refer to wg. MHP Pack bearing (354) in hook center block (350) cavity. 2. Install threaded hook end into hook center block (350) and through bearing (354). 3. Install nut (353) being careful that threads are not crossed. Tighten nut (353) until snug then back nut (353) off until first dowel pin hole is lined up. Install pins (355) until flush with nut (353) diameter. o not attempt to drive pins (355) into nut until holes are aligned or threads on hook (352) will be damaged. 4. Lubricate and install O rings (163) and (164) on sheaves (156) in grooves provided. Using a press against the inner race of bearing (157) press the bearings (157) onto both sides of sheaves (156). 5. Install the assembled sheaves in the hook center block (350). Pack cavities in hook center block (350) and hook blocks (351) with grease. 6. Tap dowel pins (165) into position. Install hook blocks (351) over bearings (157) and sheaves (156) making sure dowel holes are lined up. Secure hook blocks (351) with capscrews (356) using Loctite 242. Torque to ft lbs ( Nm). 7. Install grease fittings (360) and (363) and fill block with grease. Refer to LURITION section in Product Information Manual. 2 Lever Pendant ssembly Refer to wg. MHP ssemble protectors (261) and O rings (253) and (259) on valves (262). 2. Insert valve (262) assemblies into pendant handle (264). 3. Install screws (260) into pendant handle. 4. Install balls (256), springs (255) and plugs (254) into pendant handle. 5. Install plug (270) into pendant handle. 6. Install fittings (265) and lifting eye (250) into top of pendant handle. 7. Facing pendant handle operation side, place levers (263) such that lever direction indicators show UP on left hand side and OWN on right hand side. Install pin (257) ensuring pin inserts through levers and locates on opposite side of pendant handle. 8. Install exhaust washer (267) and secure with retainer ring (268). 9. ttach hoses to fittings located on top of pendant handle. Locate hoses to fittings as shown in the INSTLLTION section in Product Information Manual. NOTIE Screws (258) are installed in pendant levers allowing adjustment of pendant levers. 4 Lever Pendant ssembly Refer to wg. MHP ssemble protectors (261) and O rings (253) and (259) on valves (262). 2. Insert valve (262) assemblies into pendant handle (264) and attachments (right) (287) and (left) (286). 3. Install screws (260) in pendant handle and attachments (right) and (left). 4. Install balls (256), springs (255) and plugs (254) into pendant handle and attachments (right) and (left). 5. Install plug (270) into pendant handle. 6. Install fittings (265) into top of pendant handle and attachments (right) and (left). Install lifting eye (250) into top of pendant handle. 7. Facing pendant handle operation side, place levers (263) such that lever direction indicates UP on left hand side and OWN on right hand side. Install pin (257) ensuring pin inserts through levers and locates on opposite side of pendant handle. 8. Lubricate and install O rings (282) in recesses on sides of pendant handle (264). 9. Install attachment (right) (287) and (left) (286) to pendant handle (264) and secure with washers (281) and capscrews (280) and (283). Install shorter screws in back, longer screws in front. 10. Facing pendant handle operation side, place levers (285) such that lever direction indicates LEFT on left hand side and RIGHT on right hand side. Install pins (284) ensuring pins insert through levers and locate on side of pendant handle. 11. Install exhaust washer (267) in pendant handle and secure with retaining ring (268). 12. ttach hoses to fittings located on top of pendant handle. Locate hoses to fittings as shown in the INSTLLTION section in Product Information Manual. Load Test Prior to initial use, all new, extensively repaired, or altered hoists shall be load tested by or under the direction of personnel instructed in safety, maintenance and operation of this hoist. written report must be maintained on record confirming the rating of the hoist. 1. Operate the hoist fully in both directions without a load. Hoist must operate smoothly, without evidence of binding. Response to operating controls must be quick and accurate. 2. Place a 10% load on hoist and operate hoist fully in both directions. Hoist must operate smoothly, without evidence of binding. Response to operating controls must be quick and accurate. 3. ynamically load test hoist to 100% of its rated capacity in accordance with SME standards. Hoist must operate smoothly, without evidence of binding. Response to operating controls must be quick and accurate. NOTIE Testing to more than 100% may be necessary to comply with standards and regulations set forth in areas outside of the US. 10 Form MH56243 Edition 4